Scrap sorting system

ABSTRACT

A scrap particle sorting system and attendant sorting process employs a conveyor for conveying the randomly shaped particles in a random orientation, a position sensor for determining the advancement of the scrap particles in the direction of conveyance by determining the position of the conveyor belt, an image detector for periodically recording the image of a predefined viewing area through which the scrap particles are conveyed, and an image processor for periodic acquisition and processing of the images. The image processor includes logic for defining each image of the viewing area into a matrix of cells, and for each acquired image, analyzing the digital data corresponding to the image to determine for each cell in the matrix whether the pixels in that cell satisfy a predetermined criteria, and establishing a discriminator signal for each cell in the matrix as a function of that analysis. The system employs an image detector controller for receiving a signal from the conveyor position sensor and sending an activation signal to the image processor at timed intervals to acquire sequential image frames which include each of the scrap particles as they are conveyed past the viewing area, and a separator controller for receiving the discriminator signals from the image processor and for sending a control signal to selectively activate the appropriate portion of the separator to eject desired from undesired particles.

This is a continuation of application Ser. No. 08/472,182 filed on Jun.7, 1995, now abandoned, which is a divisional of application Ser. No.08/176,018, filed on Dec. 30, 1993, now U.S. Pat. No. 5,520,290.

TECHNICAL FIELD

The present invention relates to a system for sorting scrap particlesbased upon their color.

BACKGROUND ART

It is well known to sort pieces of scrap metal according to metal typeby melting the commingled scrap until the type of metal with therelatively lower melting temperature melts, thus separating it from theremaining commingled metal scraps. Considerable energy, however, isrequired to heat the scrap particles. Moreover, recovery is reducedbecause some of the particles become coated with other melted metalsduring the process.

It is also known to utilize image processing systems to sort articles bysize, shape, and/or color. However, existing image processing sortingsystems require that the articles to be sorted are conveyed in aspecific orientation through the system and/or consist of a uniform sizeand shape. Existing systems typically "scan" the image to identifyobjects matching certain pre-defined shapes. This method of processingthe image is often time-consuming. Moreover, the speed of processing isdependent upon the complexity of shape, as well as the number of objectsin the image. This approach is particularly problematic when attemptingto sort scrap particles which are unpredictably irregular in size andshape.

Another limitation to existing image processing sorting systems is thedifficulty in maintaining consistent, even illumination of the viewingarea through which the particles are conveyed.

Another drawback of existing image processing sorting systems is thedifficulty in maintaining a uniform contrasting background to theparticles.

Another drawback of the existing image processing sorting systems isthat the efficiency of the system is affected by variations in theconveyor speed due to, for example, mechanical problems such asslippage.

DISCLOSURE OF INVENTION

One object of the present invention is to provide a system for sortingscrap particles as they are transported on a conveyor which is notdependent upon the positioning of the particles on the conveyor.

Another object of the present invention is to provide a system forsorting scrap particles having widely ranging random shapes.

Another object of the present invention is to provide a system forsorting scrap particles having a wide range of reflectivity.

Another object of the present invention is to provide an imageprocessing scrap particle sorting system wherein the speed andefficiency of operation of the system is not affected by the number ofscrap particles being sorted.

Another object of the present invention is to provide a system forsorting scrap particles wherein the sorting accuracy of the system isnot affected by variations in conveyor speed due to a mechanicalproblem, such as slippage.

Another object of the present invention is to provide an imageprocessing scrap particle sorting system wherein the surface upon whichthe particles are conveyed has a uniform background.

In carrying out the above and other objects, the scrap particle sortingsystem of the present invention includes a conveyor for conveying therandomly shaped scrap particles in a random orientation, a conveyorposition sensor for determining the linear advancement of the scrapparticles in the direction of the conveyance, an image detector forelectronically recording the image of a predefined viewing area throughwhich the scrap particles are conveyed by the conveyor, and an imageprocessor for periodic acquisition and processing of the images. Theimage processor includes logic for dividing each image of the viewingarea into a matrix of cells. For each acquired image, the imageprocessor analyzes the digital data corresponding to the image todetermine for each cell in the matrix whether the pixels in that cellsatisfy a predetermined criteria, and establishes a discriminator signalfor each cell in the matrix as a function of that analysis. The systemincludes an image detector controller for receiving a signal from theconveyor position sensor and for sending an activation signal to theimage processor at timed intervals to cause the image processor toacquire sequential image frames which include each of the scrapparticles as they are conveyed past the viewing area, and a separatorcontroller for receiving the discriminator signals from the imageprocessor and for sending a control signal to selectively activate theappropriate portion of the separator to eject desired from undesiredparticles as they are dispatched from the conveyor.

The system may also include a wetting device mounted upstream from theimage detector for wetting the surface of the conveyor, thereby creatinga more uniform background for the acquired images.

The system may also include a plurality of conveyor sections locatedalong the length of the conveyor upstream from the image detector,wherein each of the sections convey the particles at progressivelyincreasing speeds, thereby progressively separating the scrap particlesfrom each other in the direction of conveyance to provide for a moreefficient processing of the acquired images.

In one embodiment, the image detector comprises an RGB color, broadcastquality CCD camera. A lighting shroud, which is illuminated by aplurality of fluorescent lights with diffuser panels interposed betweenthe lights and the viewing area, provides constant, controlledillumination of the viewing area on the conveyor.

The image processor may perform various analyses on each of the digitalpixel values recorded for an image. However, in one embodiment of thepresent invention, the system analyzes the digital values for each pixelto determine whether a predefined color criteria is met, then analyzesthe results for the pixels in each cell of the matrix and, based upon apredetermined selection criteria, establishes a discriminator signalcorresponding to each cell for output to the separator controller.Again, various criteria can be utilized for determining the value of thediscriminator signal, including frequency, location, and density of theidentified pixels. In one embodiment, the discriminator signal is merelya function of the number of pixels in that cell which satisfy the colorcriteria.

The image processing function, the image detector, conveyor positionsensor, and separator control functions, as well as other controlfunctions utilized by the system, may be performed by one or morehardware control means as desired. In one embodiment, the imageprocessor is built around an intel 80486 based CPU suitably enhanced byplug-in cards to perform image acquisition and processing, as well asdata transmission functions. The image detector control and separatorcontrol functions are embodied in a suitably programmed programmablelogic controller (PLC).

A uniformly contrasting background may be achieved by employing auniform color conveyor belt with a wetting device mounted over theconveyor belt upstream of the viewing area for spraying a liquid, suchas water, on the moving conveyor belt. The wet surface of the conveyorbelt is thereby darkened and more uniform in color than the dry belt,which often becomes faded and discolored as a result of the dust anddebris left by the scrap particles conveyed thereon.

The separator may comprise a plurality of spaced apart air nozzles whichare selectively activated in a timed fashion to direct a jet of air ontoselected scrap particles, thereby altering their trajectory as they aredischarged from the conveyor belt so that the particles are selectivelydirected into separate bins.

The system of the present invention thus provides an image processingsystem which effectively sorts randomly shaped and randomly locatedscrap particles as they are conveyed on a high speed conveyor. Becausethe image processor analyzes the images by cell, rather than attemptingto locate and examine articles of a specified size or shape, processingtime is greatly reduced and, therefore, conveyor speed and sorting rategreatly increased. Also, since the processor does not attempt todiscriminate the individual particles, processing is not affected by thenumber of particles conveyed.

These and other objects, features and advantages of the presentinvention are readily apparent from the following detailed descriptionof the best mode for carrying out the invention when taken in connectionwith the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic view of the sorting system of the presentinvention;

FIG. 2 is a perspective view illustrating one embodiment of the sortingsystem of the present invention;

FIG. 3 is a top view of the sorting system shown in FIG. 1;

FIG. 4 is a partial cut-away view of the image detector and lightingshroud utilized in the embodiment of FIG. 2;

FIG. 5 is a partial front view of the separator utilized in theembodiment of FIG. 2;

FIG. 6 is the top view of the separator utilized in the embodiment ofFIG. 2;

FIG. 7 is a diagrammatic view of a particle distributor which may beutilized by the present invention;

FIG. 8 is a flowchart of the image detector and separator controlfunctions;

FIG. 9 is a flowchart generally illustrating the image processing andresultant data transmission conducted by the image processor;

FIG. 10 is a diagram illustrating the image acquisition and processingoperations of the system;

FIG. 11 is a diagram illustrating the individual pixels in the imageviewing area;

FIG. 12 is a diagram illustrating the cells in the viewing area;

FIG. 13 is a diagram illustrating the discriminator signal values foreach cell in the viewing area for a particular image; and

FIG. 14 is a diagram illustrating an image of the viewing area includingscrap particles with a matrix superimposed thereon.

BEST MODE FOR CARRYING OUT THE INVENTION

Referring now to FIG. 1, the scrap particle sorting system of thepresent invention, generally designated as 20, includes a conveyor 22which conveys the randomly shaped scrap particles in a randomorientation through the viewing area 24 at which a series of images aredetected by the image detector 26. The viewing area 24 is illuminated ina uniform, controlled fashion by a lighting shroud 28. A position sensor30 determines the linear advancement of the conveyor 22, and thus theadvancement of the scrap particles thereon, and transmits signalsindicating this advancement to the image detector controller 32. Whenthe conveyor has advanced a distance equal to the length of the viewingarea, the image detector controller emits a control signal to the imageprocessor 34 to acquire an image of the viewing area.

After each image is acquired, the image processor 34 analyzes the datato determine, for each cell in the predefined imaginary matrixsuperimposed on the viewing area, whether the pixels in that cellsatisfy a predetermined criteria. The image processor 34 thenestablishes a discriminator signal corresponding to each cell of theimaginary matrix. These discriminator signals are then communicated to aseparator controller 36, which in a timed fashion transmits the controlsignals to the separator 38 based upon the values of the discriminatorsignals to activate selective portions of the separator in a controlledfashion to eject desired from undesired particles as they are dispatchedfrom the conveyor 22. For example, the system may sort copper or brassparticles from zinc particles by selectively directing the copper andbrass particles into a downstream bin 45, while the zinc particles aredischarged into bin 43 nearer the end of the conveyor 22.

The lighting shroud 28 is operatively connected to a lighting control40, which provides uniform illumination of the viewing area 24.

The system 20 may include a wetting device 41 which extends across thewidth of the conveyor 22 upstream from the viewing area 24, to provide aconstant spray of liquid onto the surface of the conveyor 22 to create adarkened, more uniform conveyor surface as the background.

Referring to FIGS. 2 and 3 which illustrate one embodiment of the systemof the present invention 20, the conveyor 22 comprises an endless belt42 driven by a conventional motorized head pulley 44. The image detector26 employs a three chip, RGB color CCD camera such as model XC-007,available from Sony Corporation. The camera is mounted within thelighting shroud 28 which comprises a generally rectangular frame 46covered on four sides by opaque panels 48.

The position sensor 30 comprises a commercially available timing eyecomprising, for example, LED part number 42SRU 6202, reflector number92-47 and mounting plate number 60-2008, all available fromAllen-Bradley Corporation. The LED and reflector are mounted so that thebeam is alternately transmitted through and interrupted by therectangular openings 50 which are equal in length to the opaque beltspaced therebetween. In one embodiment, the openings are one inch inlength with one inch separation between them. The components of theposition sensor 30 transmit a high signal to the image detector andseparator controllers at the leading edge of each opening 50, and a lowsignal to each of the image detector and separator controllers at thetrailing edge of each opening. The image detector controller canmaintain a count of the signals received from the position sensor 30 anddetermine whether the accumulated count equals the preset valuecorresponding to the length of the viewing area. Thus, for example, inthe embodiment where the openings are 1 inch in length with 1 inchseparation between them, when the accumulated count equals 36 (or 18high signals), the image detector controller 32 transmits a signal tothe image processor to acquire another image, then clears theaccumulated count to renew tracking the movement of the conveyor belt.The separator controller 36 can similarly maintain a count of thesignals transmitted by the position sensor 30 to determine whether thisaccumulated count equals a preset value corresponding to the length ofone row of cells in the imaginary matrix. Again, each time theaccumulated count reaches the preset value, the separator controller 36can transmit the appropriate activation signals to selectively activatethe appropriate air blast nozzles to separate selected scrap particleslocated on the conveyor in positions corresponding to the cells in thenext row of the matrix which have reached the discharge end of the belt.It will thus be appreciated that the image detector 26 and separator 38can each be synchronized with the conveyed scrap particles independentlyof any variations in belt speed.

The image processor is built around a conventional Intel 80486 basedpersonal computer. Image acquisition and storage capability may beprovided using plug-in boards such as Image-CLD and Image-1280,respectively, from Matrox Electronic Systems, Ltd. Computationallyintensive image processing functions may be performed on an additionalplug-in board of the type image-RTP, also available from MatroxElectronic Systems, Ltd. Data consisting of on/off states of air valvescould be transmitted to the separator controller using high speed serialdata transmission interface boards such as 1784-KT, available fromAllen-Bradley Corporation. The 80486 based PC forms the integratingplatform around which these various plug-in boards may be configured,programmed, and controlled.

The computer station 52 may include several conventional CRT screens54-58. Screen 54 displays the processed image for a selected image,screen 56 displays the unprocessed image detected by the camera, andscreen 58 is the operator interface screen for the image processingcomputer. Access to conventional input means, such as a keyboard, isprovided at 60. A push-button module 62 may also be utilized to providethe operator with often-used system control keys, and a stop button 64is preferably located on the front panel of the computer station 52 toprovide for quick deactivation of the system when desired.

In the embodiment shown in FIGS. 2 and 3, the computer station 52 alsoincludes the image detector control 32 and separator control 36, in theform of a suitably programmed PLC (shown in outline as 35 in FIG. 1).PLC Model No. 5/20, available from the Allen-Bradley Corporation, may beprogrammed to perform the two timing control functions associated,respectively, with activating the image detector and activating theseparator.

In the embodiment illustrated in FIG. 3, the lighting control 40 ishoused within control box 66. In this embodiment, the control comprisesone or more light controllers associated with the fluorescent bulbs inthe lighting shroud 28. Coupled to each light controller is aphotoelectric eye which is mounted within the lighting shroud (shown as80 in FIG. 4) which senses the illumination level within the shroud, andsends a signal to the light controllers in the light control box 66. Thecontrollers then automatically adjust the level of illumination of thebulbs to maintain the illumination within the shroud at a predeterminedlevel. Light controller Model No. FX1096, available from Mercron, Inc.,in Texas, may be suitably configured to perform the function of thelighting control 40.

The separator 38 comprises a plurality of air blast nozzles 70 disposedin ejector plate 68 across the width of the conveyor. The nozzles (shownin greater detail in FIGS. 5 and 6) are connected to correspondingelectrically actuated air valve assemblies in assembly box 72. The airvalve assembly comprises solenoid valves, Model No. N-721, availablefrom the Honeywell Corporation. The separator control function in thePLC 35 is programmed to transmit activation signals to selectivelyactivate the appropriate valve assemblies at the appropriate time (asdescribed in further detail hereinafter) to emit a blast of air fromselected nozzles 70 at the ejector plate 68, thereby directing selectedscrap particles away from the particle bin nearest the discharge end ofthe belt into another particle bin further downstream of the dischargeend of the belt.

Referring to FIG. 4, the lighting shroud and camera assembly of theembodiment of the system 20 shown in FIGS. 2 and 3 includes a generallyrectangular frame 46 and frame mounts 74 fabricated from suitablestructural material, such as aluminum or sheet metal. In one embodiment,four General Electric No. F48T12/CWX/HO fluorescent lamps 76 are mountedin each of the side walls defined by the frame 46. One or more fans,such as Conair Model No. MU20A1 with suitable filters, are mountedwithin the shroud to remove the heat, dust and debris from the viewingarea. A series of photoelectric eyes 80 are mounted in the side lightpanels, and are operably connected to the light controllers to provide aconstant feedback signal indicating the level of illumination within theshroud.

The outside of the side walls of the frame 46 are covered with opaquepanels (not shown) which may be fabricated from sheet metal or othersuitable material. The inside of the side walls are covered with lightdiffuser material to provide for diffuse, even lighting of the viewingarea 24. In the illustrated embodiment, the diffuser panels comprise1/4"×4'×6" white acrylic sheets. The CCD color camera is utilized as theimage detector 26, and is mounted atop the lighting shroud so that thelens of the camera projects into the illuminated area within the shroudthrough an opaque top panel 82.

Referring now to FIGS. 5 and 6, the separator 38 employs a plurality ofair blast nozzles 70 mounted across the width of the discharge end ofthe conveyor 22. The discharge end of the air blast nozzles areconnected to an ejector plate 68 through spaced apart holes and aresecured in place by set screws 86. In one embodiment, the holes arespaced one-half inch apart across the width of the conveyor 22. Thus,for example, where the imaginary cell dimension is 1/2 inch (in thedirection perpendicular to the direction of travel of the conveyor) by 1inch (in the direction of travel of the conveyor), the holes on theejector plate 68 may be positioned so that a blast nozzle mountedtherethrough is at the center of where each cell would be if one row ofcells from the imaginary matrix were superimposed over the ejector plate68. It is desirable to have correspondence of one or more nozzles 70with each cell across the width of the imaginary matrix so that theseparator control 36 can selectively signal the corresponding airnozzles for a particular cell, as required for each row in the matrixfor each image, to selectively eject the scrap particle located at thatcell position which has been determined as qualifying for separationfrom the others.

Referring to FIG. 7, the system 20 of the present invention may includean article spacer 23 located upstream from the conveyor 22 for modifyingthe extent of separation of the scrap particles prior to depositing themon the conveyor 22. The article spacer 23 may include a series ofendless belt conveyors 88, 90, 92, with each of the conveyors set totravel at progressively increasing speeds (to increase the relativeseparation of the particles in the direction of conveyance), orprogressively decreasing speeds (to decrease the relative separationbetween the scrap particles in the direction of conveyance). It will beappreciated that by utilizing these stepped conveyors, the desiredspacing can be obtained to ensure that the scrap particles are separatedby a distance generally greater than the dimension of the matrix cellsin the direction of conveyance, thereby minimizing the chance that morethan one scrap particle is in any one cell. Of course, while threeendless belt conveyors 88, 90, 92 are shown in addition to the system'smain belt conveyor 42, any number of separate conveyors may be utilizedat various speed differences depending upon the desired degree ofseparation of the scrap particles.

CAMERA AND SEPARATOR CONTROL FUNCTIONS

FIG. 8 illustrates the general flowchart for the camera and separatorcontrol functions. In one embodiment, these control functions are bothperformed by a single suitably programmed PLC which obtains beltposition information from the position sensor 30. The belt sensor 30sends the PLC a trigger signal each time it senses the leading ortrailing edge of an opening 50 on the conveyor belt 42. The PLCperiodically checks, at 94, to determine whether the accumulated beltsensor cell trigger count is equal to a number corresponding to a lengthof the conveyor belt equal to the dimension of one cell. If not, thesystem exits the sub-routine. If so, the system clears the accumulatedcell trigger count, at 96, and transmits a discriminator signal for thenext row of cells in the separator control's memory queue to the blastair valves. It should be noted that, though (as will be described infurther detail hereinafter) the image processor sends the separatormemory of the PLC a data block of binary discriminator signalscorresponding to an entire image matrix of m×n cells, the separatorcontrol logic, at 98, transmits a single row of 1×n discriminatorsignals to the air valves in a timed fashion suitable to activate theselected air valves. This data transmission is effected when the portionof the belt (and scrap particles thereon) corresponding to thatparticular row of cells has reached the discharge end of the conveyor22. It will be appreciated by the previous description that, thereafter,the valve activation signals are transmitted by the separator controllerin a row by row manner on the basis of the signals received by the beltposition sensor 30.

The separator control then indexes the accumulated belt sensor imagetrigger count, at 100, and checks to determine whether the accumulatedbelt sensor image trigger count is equal to the number corresponding tothe length of belt covered by one image. If the belt has not yettraveled a distance equal to the length of one image, the system exitsthe sub-routine at 102. If the count indicates that the belt hastraveled the length of one image, the system clears the accumulatedimage trigger count and sends a trigger signal to the image processor,at 104, to acquire another image.

Thus, it will be appreciated that the constant monitoring of theconveyor belt movement by the PLC allows for timed dispatch of theappropriate control signals to both the separator 38 and the imageprocessor 34.

Referring now to FIG. 9, each time an image trigger signal is receivedby the image processor, an image is acquired and processed as furtherdescribed hereinafter. As a result of the processing, the imageprocessor generates a block of on/off discriminator signalscorresponding to each of the cells of the matrix superimposed on theimage by the processor. This block of data is sent as a serial stream ofsize equal to one bit per cell for an entire matrix of cells coveringone image. The data is transmitted to the separator control in the PLC,where it is queued in memory. These blocks of binary discriminatorsignal data are transmitted from the image processor asynchronously fromthe subsequent row by row transmission of the signals by the separatorcontroller 36 to the separator 30. It will be appreciated that thisasynchronous transmission of data makes the image processor availablefor acquisition and processing of an adjoining section of the belt priorto when the segment that has already been processed reaches thedischarge end of the conveyor 22. In addition, the finite time intervalrequired for the receipt of the data does not influence the processingtime of the PLC since it can receive data and over-write memorysimultaneously while the separator control program is running. The DH+(Data Highway Plus) data transmission scheme utilized by Allen-BradleyPLC's is used by one of the embodiments of the invention to achieve theabove-described asynchronous data transmission.

IMAGE DETECTION

Referring to FIGS. 10 and 11, each time a new image is to be acquired,the image processor digitizes a series of analog signals transmitted bythe RGB camera and corresponding to each of the red, green and bluesegments of the color image of the viewing area. These signals areconverted by the image processor to three arrays 106, 108 and 110 (onefor red, one for green and one for blue) of approximately 480×640digital pixel values (from 0 to 255) for each of the red, green and blueimages. The 480×640 pixel arrays are the digital representations of thered, green and blue portions of the color image of the approximately 36inch by 27 inch viewing area 24. The system then normalizes each of thered, green and blue image arrays 106, 108 and 110 to correct thespectral imbalances in the light sources. In one embodiment, thisnormalization is performed by modifying each of the pixel values in thered image array 106 by a normalizing value contained in a red imagenormalizing look-up table. The green image array 108 and blue imagearray 110 are likewise each normalized using green and blue imagenormalizing look-up tables respectively. The values in each of the red,green and blue image normalization look-up tables may be obtainedthrough a calibration operation in which the operator views a neutralcolor background and digital values corresponding to the intensities ofeach of the red, green and blue domains are quantified, each,respectively, in the red, green and blue normalization look-up tables.After such calibration, the digital information acquired for the red,green and blue portions of each image may then be normalized prior toprocessing. One or more of these red, green and blue digital imagearrays 112, 114 and 116 is then processed as described below for eachacquired image to yield the selection information required to determinewhich of the scrap particles, if any, are to be separated from theothers.

In operation, the analog image signals generated by the CCD camera aredigitized by the image processor (as described above) whenever theposition sensor has determined that the conveyor belt has travelled thelength of the viewing area. Where the scrap particles are pieces ofbrass, copper and zinc metal, the conveyor is driven at speeds of up to400 feet/minute, resulting in the acquisition of digital datacorresponding to 2-3 images every second. In the interim period betweenimages, the image processor 34 processes the above-described digitalinformation as described below, and generates a series of discriminatorsignals which are transmitted to the separator controller 36. Theseparator controller 36 then selectively activates the air valves as afunction of the discriminator signals to provide an ejecting force atthe discharge end of the conveyor to eject the particles located in theselected cells of the imaginary matrix.

IMAGE PROCESSING

Referring to FIGS. 10 and 12, the image processor 34 of the presentinvention analyze the arrays of digital information, to develop anotherarray 120 of discriminator signals indicating, for each pixel in eachcell, whether that pixel satisfies a preselected criteria. In oneembodiment of the system utilized to separate brass and copper scrapfrom zinc scrap, the image processor examines the pixels to determinewhich of the pixels of the image is "red" enough to indicate thepresence of copper or brass at that pixel location. In one particularembodiment, the system subtracts the blue value from the red value foreach of the corresponding pixels in the blue array 116 and red array112, respectively, to determine whether the difference in those valuesis greater than a selected threshold, preferably 25. If the differenceis greater than 25, indicating reflection of a significant amount of thered portion of the spectrum by the object at that pixel location in theimage, the value corresponding to that pixel in the resultant array 120(shown in FIG. 12) would be set to a non-zero value. If the differencein the corresponding pixels of the red and blue arrays of FIG. 8 is lessthan 25, the corresponding pixel value in array 120 is set to zero.

In some cases, it may be advantageous to transform the image data fromthe RGB regime to a more intuitive color regime, such as HSI (hue,saturation, intensity) prior to performing the color extractionprocessing of the image (at 118). Use of any one (or more) of a varietyof color regimes to perform the color analysis is, thus, dependent uponthe particular sorting application.

As shown in FIG. 12, a value is set to one for each position in thearray corresponding to pixels which satisfy the threshold criteria andwhich are located in cell 1, 1 of the imaginary matrix. Similarly, foreach such pixel in cell 1, 2 of the matrix, the corresponding value isset to 2. Upon completion of this stage of analysis, the system therebycreates an array 120 of values which indicate those pixels in each cellof the imaginary matrix of the viewing area for which the pixel at thatlocation satisfies the preselected criteria. It will be appreciatedthat, while one embodiment of the present invention generates differentnon-zero values for each of the pixels in different cells of theresultant matrix 120 in order to allow for quick association of thenon-zero pixels with a particular cell, a simple binary scheme may alsobe employed (e.g., zero for all pixels not satisfying the color criteriaand one for all pixels satisfying the color criteria) without departingfrom the spirit of the invention.

Once this initial determination is made, the array 120 may then befurther processed to determine a one bit discriminator value for eachcell in the imaginary matrix. For example, for brass, copper/zincseparation in one embodiment, the number of pixels in cell 1,1 whichsatisfy the established criteria (i.e., are non-zero) are counted. Ifmore than 50% of the pixels in that cell satisfy the criteria, a bitcorresponding to cell 1,1 is set to one. This process is repeated foreach of the cells in the array to yield an array 122 (shown in FIG. 13)of values (0 or 1), one for each of the cells in the imaginary matrix,indicating which of the cells in that image has been selected (i.e.,which of the cells contains colors corresponding to brass or copperparticles).

It will be appreciated that a variety of separation criteria can beestablished for determining whether a particular cell has been selected.Thus, while the above-described embodiment simply counts the non-zeropixels in any particular cell and sets the discriminator signal to onewhen that count exceeds the threshold portion of the total pixels in thecell, the distribution of the non-zero pixels in a particular cell couldalso be analyzed. Additionally, the frequency and/or distribution ofnon-zero pixels in neighboring cells might be considered. However, itwill be appreciated that the relatively simple criteria utilized in theabove-described embodiment is preferable wherever it can effectivelydiscriminate between particles, since minimal processing time isemployed for each image.

Similarly, the analysis utilized to create array 120 may vary, and mayemploy any combination of the red, green and blue data of arrays 112,114, and/or 116, respectively, depending on the color discriminationbeing attempted. Again, in the application of separating copper or brassfrom zinc, both copper and brass can be easily distinguished from zincbased upon the relatively greater reflectance by copper and brass of thered portion of the spectrum from that of the zinc particles.

Thus, for example, a different, perhaps more complex, criteria may beutilized to separate copper particles from brass particles. In anyevent, the criteria should be selected so as to effectively separate theparticles as desired, while minimizing the processing time associatedwith making the pixel-by-pixel, then cell-by-cell discrimination.

SEPARATOR CONTROL LOGIC

Referring to FIG. 13, when each of the cells in a particular image havebeen analyzed, the discriminator signal values for that image may betransmitted to the separator control 36 portion of the PLC. Thediscriminator signal values for an image will typically be a data blockof m×n bits for an m×n matrix of cells. This data block is then writteninto a memory queue in the PLC. The logic in the separator control thentransmits the discriminator signals from the queue on a row-by-rowbasis. As previously described, the PLC determines, on the basis ofinformation received from the position sensor 30, when the portion ofthe belt corresponding to a particular row of imaginary matrix cells hasreached the discharge end of the conveyor. At a suitable time, the PLCtransmits the signals necessary to activate those air blast valvespositioned across the width of the conveyor at locations correspondingto cells in the non-zero cells in the current row, thereby causing anejecting force of air at each selected cell location for the currentrow. The PLC repeatedly processes the discriminator signals receivedfrom the image processor on a row-by-row basis, in this timed fashion,to effectively provide any ejecting force for each selected cell foreach row in each of the endless series of images of the travelingconveyor belt.

It will be appreciated that while the image data is acquired andanalyzed in m×n cell matrices, preferably corresponding to images of thefull 36 inch by 27 inch viewing area 24, subsequent transmission ofthose signals by the separator controller logic in the PLC isaccomplished in 1×n arrays representing a single row of cells extendingacross the 27 inch width of the conveyor belt.

It will be appreciated that the system of the present invention providesseveral advantages over prior image processing sorting systems whichallow for use of image processing in sorting scrap material. Inparticular, as illustrated in FIG. 14, for any set of scrap particlescontained in an image 126 of the viewing area, the system of the presentinvention analyzes the color information on a cell-by-cell basis, ratherthan particle-by-particle. Thus, the processing time associated withidentifying particles (whether by shape, color or otherwise) iseliminated. Processing speed is, therefore, not affected by theirregular shapes and sizes of the particles. Instead, the air nozzles ofthe separator are selectively activated on the basis of colordiscrimination for each cell in each row of the imaginary matrix of theviewing area to provide an ejecting force when the particles located onthe conveyor belt in the positions corresponding to a particular row ofcells in the imaginary matrix reaches the discharge end of the belt.Thus, when, for example, the portion of the belt depicted in imaginaryrow of cells 128 reaches the discharge end of the conveyor, thediscriminator signals transmitted to the PLC will result in activationof the air nozzles at cell locations 129, 130 and 132. In the nextperiod of time during which the portion of the belt depicted in thefollowing row 134 is at the discharge end of the conveyor, the PLC willactivate the air nozzle(s) in the area of cells 136 and 138.

While the specific embodiments disclosed herein contemplateimplementation of the image processing, image detector, and separatorcontrol functions on separate hardware platforms, these functions couldbe integrated around a single multi-tasking computer capable ofinterrupt driven operation without departing from the spirit of theinvention.

While the best mode for carrying out the present invention has beendescribed in detail, those familiar with the art to which this inventionrelates will recognize various alternative designs and embodiments forpracticing the invention as disclosed by the following claims.

What is claimed is:
 1. A method for sorting scrap particles based uponcolor including the steps of:conveying the scrap particles on an opaquebelt conveyor having a surface providing a uniformly contrastingbackground for the particles; determining the position of the conveyor;providing constant, controlled illumination of different preselectedwavelengths at a pre-defined viewing area along which the particles areconveyed by the conveyor; acquiring data corresponding to a color imageof the viewing area at timed intervals based upon the location of theconveyor; employing an image processor computer to divide the viewingarea into an imaginary matrix of cells and analyze the datacorresponding to the image of the viewing area, independently of thepresence or absence of particles in the viewing area, to determine foreach cell in the matrix whether the color of the image in that cellsatisfies a predetermined color criteria, and generate a discriminatorsignal for each cell of the matrix as a function of the comparison ofeach cell of the matrix with the predetermined color criteria; andsending a control signal to activate a separator located downstream fromthe image detector as a function of the discriminator signal toselectively actuate the separator to separate desired from undesiredparticles.
 2. The method of claim 1 including the step of wetting thesurface of the conveyor, thereby creating a more uniform background forthe image of the particles supported and conveyed thereon.
 3. The methodof claim 1 wherein the conveyor comprises a plurality of endless beltconveyor sections and including the step of increasing the separation ofthe objects in the direction of conveyance by moving each subsequentconveyor section at a relatively faster speed than the immediatelypreceding conveyor section.
 4. The method of claim 1 including the stepof removing heat, dust and debris from the viewing area.
 5. The methodof claim 1 wherein each cell in the matrix includes a plurality ofpixels, each pixel having a digital value corresponding to the imageacquired by the image detector, and wherein the image processor computerfurther performs the steps of:providing a resultant array of memorylocations corresponding to the total number of pixels in the image;providing a discriminator signal array of memory locations correspondingto the array of cells in the matrix; determining for each pixel whetherthe value of that pixel satisfies a predetermined color criteria andsetting a value in the location in the resultant array corresponding tothat pixel as a function of the color criteria determination; anddetermining for each cell whether the values in the resultant arraycorresponding to pixels in that cell satisfies a predeterminedseparation criteria and setting a value in the location in thediscriminator signal array corresponding to the cell as a function ofthe separator criteria determination.
 6. The method of claim 5 whereinthe separation step includes determining whether the color criteria issatisfied by a preselected minimum number of pixels in the cell.
 7. Themethod of claim 5 wherein the separation step includes determiningwhether those pixels in the cell satisfying the color criteria satisfy apreselected distribution criteria.
 8. The method of claim 5 furtherincluding the step of setting the value in the resultant array tonon-zero for each pixel satisfying the color criteria and to zero foreach pixel not satisfying the color criteria.
 9. The method of claim 8further including the step of associating a unique value with each ofthe cells, and where each of the non-zero values in the resultant arrayare set to the unique value of the cell in which the associated pixel islocated.
 10. A computer-implemented method for sorting randomly-shapedscrap particles as they are conveyed in random locations on a movingconveyor through a pre-defined viewing area, including the stepsof:acquiring data corresponding to an image of the viewing area;dividing the viewing area into a matrix of cells, each cell including aplurality of pixels, defining a resultant array of memory locationscorresponding to the total number of pixels in the image; defining adiscriminator signal array of memory locations corresponding to thetotal number of cells in the matrix; determining for each pixel,independently of the presence or absence of particles in the viewingarea, whether the data in that pixel satisfies a predetermined colorcriteria and setting a value in the location in the resultant arraycorresponding to that pixel as a function of the color criteriadetermination; determining for each cell whether the values in theresultant array corresponding to pixels in that cell satisfies apredetermined separation criteria; setting a value in the location inthe discriminator signal array corresponding to the cell as a functionof the separator criteria determination; and sending a control signal toactivate a separator located downstream from the image detector as afunction of the discriminator signal to selectively actuate theseparator to separate desired from undesired particles.
 11. The methodof claim 10 wherein the separation criteria includes a determination ofwhether the color criteria is satisfied by a preselected minimum numberof pixels in the cell.
 12. The method of claim 10 wherein the separationcriteria includes a determination of whether those pixels in the cellsatisfying the color criteria satisfy a preselected distributioncriteria.
 13. The method of claim 10 further including setting the valuein the resultant array to non-zero for each pixel satisfying the colorcriteria and to zero for each pixel not satisfying the color criteria.14. The method of claim 10 further including associating a unique valuewith each of the cells, and where each of the non-zero values in theresultant array are set to the unique value of the cell in which theassociated pixel is located.
 15. A method for sorting scrap particlesbased upon color as the particles are conveyed on a moving conveyor; themethod comprising:determining the position of the conveyor; periodicallyacquiring an image of a defined viewing area on the conveyor; employinga computer image processor for receiving from the image detector thedata corresponding to an image of the viewing area, dividing the viewingarea into a matrix of cells, wherein each cell includes a plurality ofpixels, determining for each cell in the viewing area, independently ofthe presence or absence of particles in the viewing area, whether thepixels in that cell satisfy a predetermined separation criteria, andtransmitting a discriminator signal corresponding to each cell;employing a first computer controller for receiving a signal from theposition sensor, determining whether the conveyor has moved a distanceequal to the length of the viewing area, and as a function of thatdetermination, sending an activation signal to acquire an image; andemploying a second controller for receiving a signal from the positionsensor, determining whether the conveyor has moved a distance equal tothe length of a cell, and sending a control signal to activate aseparator located downstream from the image detector as a function ofthe discriminator signal received from the image processor to separatedesired from undesired objects.
 16. A method for sorting scrap particlesbased upon color including the steps of:conveying the scrap particles onan opaque belt conveyor having a surface providing a uniformlycontrasting background for the particles; determining the position ofthe conveyor; providing constant, controlled illumination of differentpreselected wavelengths at a pre-defined viewing area along which theparticles are conveyed by the conveyor; removing heat, dust and debrisfrom the viewing area; acquiring data corresponding to a color image ofthe viewing area at timed intervals based upon the location of theconveyor; employing an image processor computer to divide the viewingarea into an imaginary matrix of cells and analyze the datacorresponding to the image of the viewing area, independently of thepresence or absence of particles in the viewing area, to determine foreach cell in the matrix whether the color of the image in that cellsatisfies a predetermined color criteria, and generate a discriminatorsignal for each cell of the matrix as a function of the comparison ofeach cell of the matrix with the predetermined color criteria; andsending a control signal to activate a separator located downstream fromthe image detector as a function of the discriminator signal toselectively actuate the separator to separate desired from undesiredparticles.